Thread: Cutting thin acrylic.

I've been having more sucess with a dremel, it just gets better with practice. I'm a hands on sorta guy.
Thanks all for the replies..

thanks for the good info on finishing. I have used maas after sanding witthh good results.

Here are some good hints to think about while cutting acrylic plastic.

My best choice for cutting the stuff would be a scroll saw.

1) If the acrylic has been delivered still covered by its protective paper on both sides, then do not remove that protective papuer until after you have done your cutting. This can help prevent a little bit of the splintering that happens on the edge.

2) An even better way to help prevent edge splintering and cracking is to sandwich the acrylic between two pieces of scrap plywood (1/8" to 1/4" each side). This will definitely allow you to get a cleaner cut with less jumping and grabbing of the sawblade. To make this sandwich I would use either little nails (brads) or tape along the edges to fix all layers tightly to one another for the duration of the cutting process. The wood sawdust from the wooden sandwich portion may also help a little bit to prevent the plastic dust from re-welding itself in the kerf during the cutting process.

3) Lubricate the blade slightly. Some paraffin wax from a candle held to the blade occasionally will help.

1971wedge
this is one I did a while back.
http://straightrazorpalace.com/attac...odur-mike1.jpg

Nice scales! I noticed the stress cracking at the end pins.

Not to cause a panic, but to acquaint you with some work shop possibilities. Here is a short note on Acrylic annealing:

Occasionally, If plastics are overheated while buffing, machining, sawing, or if over stressed while fastening, it may become very brittle and will stress crack. The cause is internal stress, built up by cooling of the part at different rates after the process. That may cause future problems if it is subjected to washing with alcohol or some strong cleaners. The only remedy is to not overheat any surface while machining or buffing. If the Acrylic has possibly been over heated, it may be annealed by application of heat to about 18oºF till it is at the same temperature throughout and held at that temperature held for for an hour or two and then allowed to cool very slowly. It is best to have it pressed between flat surfaces. Try it on some sheet you can risk. I have used a couple clean 1/8th inch thick aluminum sheets and almost boiling water in a large pan, ~180º-190ºF.
Think of all the plastic boxes that you've seen with crazing marks internal to the plastic..
Here is a link to a very good short article.
MINIMIZE IMPACT OF STRESS ON ACRYLIC SHEET THROUGH ANNEALING: Plastic Distributor & Fabricator

Bye the way, "Cast Acrylic" from a supplier will survive working processes with less internal stress as there is no manufacturing stress built into it. Altogether a better idea for making razors to be passed on for generations. Extruded acrylic has internal stresses from the manufacturing process.

Respectfully
~Richard

Nice, where did you get your clear acrylic at?
Aaron

Originally Posted by oldblades

1971wedge
this is one I did a while back.
http://straightrazorpalace.com/attac...odur-mike1.jpg

I stick both sheets of acrylic together with double sided tape and with the brown paper is left on. I stick my paper template to that and cut then both sides out together using a band saw. With them still together I shape the scales using a belt sander and a Dremel. I then sand and polish the edges.

I only separate the two scales prior to fitting the wedge. Until then all the work is done on both scales at once, treating them as a single piece of acrylic. This is how you get them to both come out exactly the same.

Aaron
I get it from Delvie's plastic or Interstate plastic.
I use cell cast acrylic.
Tim

Nice job, Legion! I like the fog Acrylic!
Respectfully,
~Richard

Originally Posted by oldblades

1971wedge
this is one I did a while back.
http://straightrazorpalace.com/attac...odur-mike1.jpg

Tell us about your lettering process on the scales!